Production of novelty yarns, fabrics, and the like



July 31, 1951 D. R. BARCELO EI'AL 2,562,760

PRODUCTION OF NOVELTY YARNS, FABRICS, AND THE LIKE Filed Oct. 13, 1948 2 Sheets-Sheet l- Jul 31, 1951 R BA l- Erm- 2,562,760

PRODUCTION OF NOVELTY YARNS, FABRICS, AND THE LIKE 2 Sheegs-Sheet 2 Filed Oct. 15, 1948 fiauz'el/Rfiarcelo fedraA/llaso vZ W Patented July 31, 1951 TENT OFFICE PRODUCTION OF NOVELTY YARNS, FABRICS, AND THE LIKE Daniel Rogla Barcelo and Pedro Alsina Maso, Barcelona, Spain, assignors to American Enka Corporation, Enka, N. 0., a corporation of Dela- Ware Application October 13, 1948, Serial No. 54,264 In the Netherlands February 18, 1948 the invention is directed to the manufacture of l simulated shantung from variable denier rayon.

It is known to manufacture artificial thread with periodic denier variations throughout its length by various systems. Those usually employed include, for example, a variable drive for the spinning pump that extrudes the thread, spinning pumps provided with several plungers in which the pressure chamber that serves to keep the ressure constant has been omitted, plunger pumps with plungers of unequal diameter, gear wheel pumps with uneven teeth, gear wheel pumps in which some of the teeth have been removed. from the gear wheels, a main spinning pump with auxiliary plunger pumps which act in a variable manner and supply extra spinning solution, membrane or plunger pumps which do not supply the spinning solution but function to effectpressure fluctuations in the line from the spinning pump to the spinneret.

A typical example of an arrangement in which an extra supply of spinning solution is supplied to a spinneret, is disclosed in United States Patent No. 2,142,597. However, in this arrangement, and in all the above mentioned systems, the'denier variations follow a definite and fixed pattern; or in other words, even though the denier variations may be aperiodic throughout a definite length of yarn, the same pattern repeats itself at intervals.

Attempts have also been made tostretch the thread in a variable manner between a spinneret and a positively driven draw-off device, such as a godet or the like. For this purpose a non-circu lar eccentrically driven draw-01f device is employed which tends to pull or stretch the thread in a jerky or variable manner. Another mechanism for doing the same thing includes a jerky movement of the spinneret per se, which has the tendency to effect a lengthening or shortening of the thread.

A typical example of drawing the thread from the bath in a variable manner by means of an eccentrically driven non-circular godet, is disclosed in United States Patent No. 2,120,990; The patentees in this case are attempting to produce a thread having aperiodicdenier variations and seek to achieve this resultby omitting some of the gear wheel teeth-that drive the godet. This arrangement may produce aperiodic denier variations for a certain period, but sooner or later this unsystematic formation of thick and thin places 9 Claims. (01. 18 -8) 4; and

in the thread will form a pattern which will be repeated. These patentees, as well as others, have attempted to combine several of the above described methods in an effort to' form aperiodic denier variations in thread. However, these attempts have not been completely successful, and consequently prior to the present invention it has not been possible to manufacture from artificial threads a simulated shantung fabricin which the distribution of the thick and thin portions of the thread, or the formation of nubs therein, was at random and purely accidental.

It is therefore an object of the present invention to provide a process which will produce an artificial thread with aperiodic denier variations throughout'its entire length which renders the thread suitable for weaving an imitation shantung fabric.

Another object of this invention is the provision of an apparatus that embodies a disturbing means which is not positively connected to a driving mechanism.

It is further contemplated to provide an element that is not positively driven but which is rotated by the thread per se, which results in a haphazard slippage between the thread and element and is entirely dependent on accidental circumstances that govern the said slippage.

An additional object of this invention is to provide a system which is characterized by supplying a spinning solution to a spinneret in a varying or pulsating manner, and the thus formed threads are withdrawn from the bath by a positively driven godet, and between the spinneret,

Figure 2;

Figure 4 is a detailed view of the drive for the spinning pump in partial sectz' n; Figure 5 is a view taken on line 5-.-5 of Figure Figures 6 and ,7 show details of the ratchet and pawl arrangement for driving thevpump shaft a spinning pump III which forces the spinning solution through a filter H and thence through spinning tube I2 and spinneret [3. As this spinning solution passes through the spinneret, a thread l4, consisting of a multiplicity of filaments is formed and drawn through a coagulating bath by means of a positively driven draw-off device [6.

The spinning pump I per se is of conventional design but is so driven that the spinning solution is extruded at a varying rate. This is accomplished by driving from a shaft I! which is connected to a source of power not shown. The shaft I1 is provided with a pinion [8 which is keyed thereto and which meshes with a gear l9 mounted over at ratchet and pawl assembly 20. As the shaft 11 is rotated in a clockwise direction as viewed in Figure this movement is imparted to pinion I8 which rotates the gear I9, and through the ratchet and paWl assembly 20, the movement is imparted to a shaft 21 which is connected to the spinning pump ID. If reference is made to Figure 6'it will be noted that the ratchet and pawl assembly 20 is comprised of three double pawls 22, 23 and 24 which are connected to and carried by the gear IQ for rotation therewith. These pawls are spring urged into engagement with a ratchet sleeve 25 which is keyed to the shaft 2 I.

This ratchet sleeve 25 is hollow and elongated and is connected by bolt 26 to the shaft 2| at the right end thereof which is not provided with teeth. A bolt 21 having an unthreaded bearing surface near its head is threaded into the left end of the ratchet sleeve 25 and supports therefrom the gear I9. The gear I9 is connected to a disc 28 which turns freely on the unthreaded portion of the boIt'Z'I. A washer 29 is interposed between the disc 28 and the head of the bolt 21.

Thus when the gear [9 is rotated in a counterclockwise direction as viewed in Figure 5 the pawls are rotated with it and are urged into the teeth of the ratchet sleeve 25 whereby the shaft 2| is also driven in a counterclockwise direction as viewed from that Figure.

The movement just described is continuous in nature and would not of itself be productive of denier variations or other variation in the output of the pump. However, there are also coacting with another axial portion of the ratchet sleeve 25 a pair of double pawls 30 and 31 (see Figure 7). These pawls are mounted on a disc 32 which is provided with a spring arm 33 and a projecting portion 34. The spring arm 33 is connected to a spring 35 which is anchored at one end on a "bar 36 and is wrapped around a hub 31 which functions as a spacer between the gear I9 and the disc 32. Thrust of the spring 35 is such as to urge the disc 32 in a clockwise direction as it is viewed in Figures 5 and 7. The hub 31 is provided with lubrication rings 38 and 39 which bear against the gear I!) and the disc 32. This hub assembly is keyed to the sleeve 25 by a pin 40.

Coacting with the projection 34 of the disc 32 there are three lugs 4|, 42 and 43 that are attached to a disc 44 which is keyed to the drive shaft I! for rotation therewith. It can now be understood how a variation in output capacity of the pump l0 can "be produced for, periodically during the operation of the pump at a constant speed predetermined by the ratio of the gears l8 and I9, one of the lugs 4|, 42 or 43 strikes the projection 34of the disc 32 and angularly displaces the disc 32 in a counterclockwise direction as it is viewed in Figure 5. Due to the fact that the disc 44 is of greater diameter than 7.5,

the gear l8 this movement in an angular sense occurs at a greater speed than the movement of the periphery of the gear l8 despite the fact that gear 18 and disc 44 are both keyed to shaft H.

For purposes of description, reference may be made to the action which occurs immediately subsequent to the positioning of the elements set forth in Figure 5. In this case the lug 42, moving in a clockwise direction, engages the projection 34 on the disc 32 and moves the disc 32 at an accelerated rate in a counterclockwise direction for a few degrees until the lug 42 and the projection 34 no longer engage. During this movement the shaft 2| is revolving at a greater rate of speed than the gear 19. Accordingly, the ratchet sleeve 25 will be rotating in a counterclockwise direction at a speed greater than the pawls 22, 23 and 24. This condition, however, simply results in free wheeling of the clutch established by the ratchet and pawl assembly 20 so that the drive through the disc 32 momentarily replaces the drive through the gears l8 and [9. Since the disc 32 during the period of engagement of the lug 42 with the projection 34, is rotated in a counterclockwise direction, the driving pawls 30 and 3| during that period actually drive the pump shaft 2|. After the lug 42 and the projection 34 are no longer in engagement and before the lug 43 reaches the position of lug 32 in Figure 5, the spring 35 acts on the disc 32 and rotates the same in a clockwise direction until the projection 34 substantially returns to the Figure 5 position. As this is accomplished the drive to the. pump is again under the control of the gears l8 and I9 which are driving through the pawls 22, 23 and. 24. However, the disc 32 is moving in a clockwise direction and its pawls are free wheeling on the ratchet sleeve 25 which, of course, is turning in a c0unterclockwise direction because of the action of the gears l8 and I9 and the ratchet and pawl assembly 20.

The above described spinning pump drive merely exemplifies one suitable way of forcing the spinning solution through the spinneret in a pulsating manner. Obviously, other mechanism might be used to effect the same result. The apparatus as thus far described will vary the amount of spinning solution supplied to the spinneret which of itself will form thick and thin portions in the thread in a periodic manner if the thread is drawn from the spinneret under a uniform tension.

In .order to inject a haphazard irregular recurrence of thick and thin portions or hubs in the thread l4 as it is extruded, there is interposed between the spinneret l3 and the draw-off device IS, a freely rotatable, heart-shaped, thread-guiding element or disk 45. This thread guiding element 45 is eccentrically mounted on an axle 46 and is retained in rotative position by means of collars 41 and 48 (see Figure 2). Also by reference to this figure it will be seen that thread guiding element 45 is provided with a concave thread guiding groove 49.

In the operation of the system the spinning solution is forced through the spinneret, and due to the fact that the supply of the solution varies as a result of the variable drive of the spinning pump, a thread is formed having denier variations therein. As the thread is coagulated in the spin bath and withdrawn therefrom by means of a positively driven godet, it i passed around the freely rotatable eccentric thread guidin element or disk and the movement of the thread therearound causes the disk to rotate. Due to the eccentricity of the disk, the thread-which is still very pliable and already contains irregularities, is influenced in an unusual manner. It was determined that the disk, driven eccentrically solely by the thread, caused the thread to fortuitously slip at times, and at other times fortuitously adhere thereto without any slippage. epending on the accidental position of the disk, the path of the thread and the pressure of the thread on the disk varies, which in turn causes the velocity of the disk to vary. The haphazard slippage and friction of the thread on the disk during the passage of the thread from the spinneret to the collection device results in the formation of aperiodic denier variations which never form a pattern. Moreover, since the degree of coagulation varies in the thick and thin portions of the thread and this is accentuated by the change in the path of travel of the thread during each revolution of the disk, further irregularities are introduced.

The eccentric disk can be manufactured from any suitable material that is acid resistant, and for different types of thread, can be either Weighted or hollow in the center, so as to adapt the weight of the disk to the strength of the thread.

As a result of forming a variable denier thread by means of a variable feed pump and superimposing a nonuniform pulling action by means of a thread driven eccentric, it was found that the thread in its final form contained denier variations without period and without any pattern formation. With this arrangement, it is also possible to achieve large differences between the thick and thin portions of the thread. Depending on the dimensions of the disk, the eccentricity thereof and the composition of the coagulating bath, etc., differences between the thick and thin portions of the thread may vary as much as 1:3, 1:4 and 1:5, or even more.

This system can be successfully employed in any rayon plant in which a spinning solution is extruded through spinnerets and coagulated in an acid spin bath. It can also be used for the manufacture of threads having aperiodic denier variations and spun accordin to the dry spinning method wherein the spin bath is replaced by a spinning cell and gas or steam is used as the coagulating medium. The essence of the invention is combining a thread-driven, threadvariations in fabrics results in a fabric that simulates shantung to a much better degree than has heretofore been possible.

The invention is to be restricted only to the extent defined in the appended claims.

What is claimed is:

1. An apparatus for the production of synthetic threads having aperiodic denier variations therein which comprises a spinneret, means for pumpin a spinning solution through the spinneret in a pulsating manner to form a variable denier thread and means driven solely by, and directly from, the thread for drawing the thread from the spinneret at an irregularly varying linear speed whereby to effect haphazard recurrence of thick and thin portions in the thread.

2. An apparatus for the production of synthetic threads having aperiodic denier variations therein which comprises a spinneret, means for pumping a spinning solution through the spinneret in a pulsating manner to form a variable denier thread and an eccentric disk driven solely by, and directly from, the thread for drawing the thread from the spinneret at an irregularly varying linear speed whereby to effect haphazard recurrence of thick and thin portions in the thread.

3. An apparatus for the production of synthetic threads having aperiodic denier variations therein which comprises a spinneret, a spinning pump provided with a rotatable shaft, a constant drive and an auxiliary drive for the pump shaft to increase the peripheral speed of the shaft at intervals in order to pump a spinning solution through the spinneret in a pulsatin manner to form a variable denier thread, positively driven means for drawing the thread from the spinneret and an eccentric heart-shaped disk interposed between the spinneret and drawofi means driven solely by the thread to cause the thread to travel at an irregularly varying linear speed whereby to effect haphazard recurrence of thick and thin portions in the thread.

4. An apparatus for the production of viscose rayon threads having aperiodic denier variations therein which comprises a spinneret located in a coagulating bath, a spinning pump provided with a rotatable shaft, a constant drive and an auxiliary drive for the pump shaft to increase the peripheral speed of the shaft at intervals in order to pump a spinning solution through the spinneret in a pulsating manner in the coagulating bath to form a variable denier thread, positively driven means for drawing the thread from the bath and an eccentric heart-shaped disk interposed between the spinneret and draw-off means driven solely by the thread to cause the thread to travel at an irregularly varying linear speed whereby to effect haphazard recurrence of thick and thin portions in the thread.

5. A method for the production of thread of synthetic origin having aperiodic denier variations therein throughout its entire length which comprises pumping a spinnin solution through a spinneret in a pulsating manner into a coagulating medium, and drawing the thus formed thread through the medium by a positively driven constant-velocity draw-off device, while superimposing tension variations of an irregular and random pattern upon said thread during its passage between said spinneret and said drawoff device to produce further haphazard denier variations in said thread.

DANIEL ROGLA BARoELo. PEDRO ALSINA MASO.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,996,796 Dreyfus et a1 Apr. 9, 1935 2,120,990 Picard et a1 June 21, 1938' 2,2 0,403 Heim Nov. 5, 1940 2,468,666 Heim Apr. 26, 1949 

3. AN APPARATUS FOR THE PRODUCTION OF SYNTHETIC THREADS HAVING APERIODIC DENIER VARIATIONS THEREIN WHICH COMPRISES A SPINNERET, A SPINNING STANT DRIVE AND AN AUXILIARY DRIVE FOR THE PUMP SHAFT TO INCREASE THE PERIPHERAL SPEED OF THE SHAFT AT INTERVALS IN ORDER TO PUMP A SPINNING SOLUTION THROUGH THE SPINNERET IN A PULSATING MANNER TO FORM A VARIABLE DENIER THREAD, POSITIVELY DRIVEN MEANS FOR DRAWING THE THREAD FROM THE SPINNERET AND AN ECCENTRIC HEART-SHAPED DISK INTERPOSED BETWEEN THE SPINNERET AND DRAWOFF MEANS DRIVEN SOLELY BY THE THREAD TO CAUSE THE THREAD TO TRAVEL AT AN IRREGULARLY VARYING LINEAR SPEED WHEREBY TO EFFECT HAPHAZARD RECURRENCE OF THICK AND THIN PORTIONS IN THE THREAD. 